Method and apparatus for repair of vehicle door handles

ABSTRACT

A repair kit can be used to repair broken interior door handle assemblies on certain vehicles, and replaces the original equipment door handle support housing with a replacement housing, without having to replace the entire door panel. The method includes removing the original (broken) door handle housing from the back side of the door panel by drilling or otherwise removing the plastic rivets that secure the original handle housing to the door panel. The replacement housing is then installed on the back side of the door panel in place of the original and screws are installed into drilled-out plastic rivet locations in the door panel through apertures in the replacement door handle housing to secure the replacement door handle housing to the door panel.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. applicationSer. No. 13/532,661, filed Jun. 25, 2012, which claims the benefit ofthe filing date of U.S. Provisional Patent Application Ser. No.61/500,170, filed Jun. 23, 2011. The foregoing applications areincorporated by reference in their entirety as if fully set forthherein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

TECHNICAL FIELD

The present invention relates generally to vehicles and vehicle repair,and more particularly to an improved method and apparatus for the repairof certain types of original equipment interior door handles onvehicles.

BACKGROUND INFORMATION AND DISCUSSION OF RELATED ART

Some vehicles, including many Jeep Grand Cherokees from the 2004 to 2011model years, and Jeep Commanders from the 2006 model year to thepresent, appear to have a weak area in the interior door handles, andmany of the handles in these vehicles have broken over time.Unfortunately, the interior door handles on some of these vehicles areintegrated into the door panel and are generally not serviceable bythemselves, instead, the entire interior door panel has to be replacedin order to replace the door handle. For example, the interior doorhandle housing on the aforementioned Jeep vehicles is not attached withscrews but is plastic welded into the door panel. On many other types ofvehicles, the interior door handles are serviceable by themselves, whichmakes the repair much less expensive.

The foregoing information reflects the current state of the art of whichthe present inventor is aware. Reference to, and discussion of, thisinformation is intended to aid in discharging Applicant's acknowledgedduty of candor in disclosing information that may be relevant to theexamination of claims to the present invention. However, it isrespectfully submitted that none of the above-indicated informationdiscloses, teaches, suggests, shows, or otherwise renders obvious,either singly or when considered in combination, the invention describedand claimed herein.

SUMMARY OF THE INVENTION

The method and apparatus for the repair of vehicle door handles of thepresent invention provides an interior door handle repair kit that canbe used to repair broken interior door handle assemblies on certainvehicles such as the Jeep Grand Cherokee (e.g., model years 2004 to2011) and Jeep Commander (e.g., model years 2006 to the present). Theinventive kit permanently solves the problem of prematurely broken doorhandles by replacing the brittle original equipment door handle supporthousing with a replacement housing constructed of very strong compositematerial, and includes all the components and fasteners necessary torepair the interior door handles on one or all of the doors, withouthaving to replace the entire door panels.

The inventive method includes removing the original (broken) door handlehousing from the back side of the door panel by drilling or otherwiseremoving the plastic rivets that secure the original handle housing tothe door panel. The posts and tab(s) that extend from the back side ofthe door panel through corresponding apertures in the original housingare not removed, and are maintained for later use. After the rivets havebeen removed, the original door handle housing can be removed from thedoor panel and discarded. The replacement door handle housing is theninstalled on the back side of the door panel over the original posts andtab(s), and push nut retainers or other fasteners are placed over theposts and pushed down to press the flange of the replacement housingtightly against the back side of the door panel. A hole is drilledthrough the base of the tab, and a cotter pin or other fastener isinserted through the hole and bent around the tab to similarly securethe flange of the replacement housing tightly against the door panel.

As an alternative to, or in addition to, the use of retainers on thepost(s) and cotter pin or screw at the tab(s), small screws (preferablywith washers) may be installed into one or more of the former plasticrivet points to secure the replacement door handle housing to the doorpanel.

The inventive repair kit preferably includes replacement interior doorhandle support housings for all four doors (driver's front door,driver's side rear passenger door, passenger side front door, andpassenger side rear door); push nut retainers, cotter pins, screws, andwashers; and simple detailed instructions with pictures forinstallation. The original color for the kit components may be grey,tan, or other original equipment color, or the parts can be painted tomatch door panels, or may be used without matching colors. Thecomponents of the repair kit may be modified to provide a correspondingkit for other vehicles.

It is therefore an object of the present invention to provide a new andimproved vehicle interior door handle repair kit.

It is another object of the present invention to provide a new andimproved method for replacing the original equipment door handle housingwith a replacement housing constructed of very strong compositematerial.

Other novel features which are characteristic of the invention, as toorganization and method of operation, together with further objects andadvantages thereof will be better understood from the followingdescription considered in connection with the accompanying drawings, inwhich preferred embodiments of the invention are illustrated by way ofexample. It is to be expressly understood, however, that the drawingsare for illustration and description only and are not intended as adefinition of the limits of the invention. The various features ofnovelty which characterize the invention are pointed out withparticularity in the claims annexed to and forming part of thisdisclosure. The invention resides not in any one of these features takenalone, but rather in the particular combination of all of its structuresfor the functions specified.

There has thus been broadly outlined the more important features of theinvention in order that the detailed description thereof that followsmay be better understood, and in order that the present contribution tothe art may be better appreciated. There are, of course, additionalfeatures of the invention that will be described hereinafter and whichwill form additional subject matter of the claims appended hereto. Thoseskilled in the art will appreciate that the conception upon which thisdisclosure is based readily may be utilized as a basis for the designingof other structures, methods and systems for carrying out the severalpurposes of the present invention. It is important, therefore, that theclaims be regarded as including such equivalent constructions insofar asthey do not depart from the spirit and scope of the present invention.

Further, the purpose of the Abstract is to enable the U.S. Patent andTrademark Office and the public generally, and especially thescientists, engineers and practitioners in the art who are not familiarwith patent or legal terms or phraseology, to determine quickly from acursory inspection the nature and essence of the technical disclosure ofthe application. The Abstract is neither intended to define theinvention of this application, which is measured by the claims, nor isit intended to be limiting as to the scope of the invention in any way.

Certain terminology and derivations thereof may be used in the followingdescription for convenience in reference only, and will not be limiting.For example, words such as “upward,” “downward,” “left,” and “right”would refer to directions in the drawings to which reference is madeunless otherwise stated. Similarly, words such as “inward” and “outward”would refer to directions toward and away from, respectively, thegeometric center of a device or area and designated parts thereof.References in the singular tense include the plural, and vice versa,unless otherwise noted.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to thefollowing detailed description thereof. Such description makes referenceto the annexed drawings wherein:

FIG. 1 is a front elevation view of a broken door handle on an interiordoor panel of a vehicle;

FIG. 2 is a rear view of the original door handle housing being removedfrom the back side of the door panel;

FIG. 3 is a rear view of a replacement door handle housing installed onthe back side of the door panel; and

FIG. 4 is a view of screws being installed into drilled-out plasticrivet points to secure a replacement door handle housing to a doorpanel.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 through 4, wherein like reference numerals refer tolike components in the various views, there is illustrated therein a newand improved method and apparatus for the repair of vehicle interiordoor handles.

FIG. 1 is a front elevation view of a broken door handle assembly 10 onan interior door panel 12 of a vehicle. Door handle assembly 10 includeshandle support housing 14 and handle lever 16.

FIG. 2 is a rear view of the original (broken) door handle housing 20 inthe process of being removed from the back side of the door panel 12.Drill 22 is being used to drill out the plastic rivets 23 that plasticwelded and permanently secured the original handle housing 20 to thedoor panel 12. Alternatively, a razor knife or other tool could be usedto remove the rivets. Posts 24 and tab 26 extend from the back side ofthe door panel through corresponding apertures in the original housing,but are not removed, and are maintained for later use. After the rivetshave been removed, the original door handle housing can be removed fromthe door panel.

FIG. 3 is a rear view of a replacement door handle housing 30 havingbeen installed on the back side of the door panel 12 in place of theoriginal. Push nut retainers 32 have been placed over the posts 24 andpushed down to press the flange 34 of the replacement housing tightlyagainst the back side of the door panel. Alternatively, spring clips,locking tabs, or other fasteners could be used on the posts to retainthe replacement housing against the door panel. A hole 36 has beendrilled through the base of tab 26, and cotter pin 38 has been insertedthrough the hole 36 and bent around the tab to similarly secure theflange of the replacement housing tightly against the door panel. As analternative to the use of a cotter pin, a screw may be installed intothe tab (preferably at an angle that tightens the handle to the panel).

Alternatively or optionally, adhesive may be applied between the flangeof the replacement housing and back side of the door panel (prior totightening of the push nuts and placement of the cotter pin in the tab,if they are used) to provide bonding and help prevent gaps between thesurfaces.

FIG. 4 is a view of screws 40 being installed into drilled-out plasticrivet locations or points 42 in a door panel 44 through apertures 46 ina replacement door handle housing 48 to secure the replacement doorhandle housing to the door panel. The use of screws to secure thereplacement door handle housing may be used in addition to, or insteadof, the use of retainers on the post(s) and cotter pin or screw at thetab(s).

Typical customer instructions for the repair of broken interior doorhandles on a Jeep Cherokee type vehicle may include the following:

Tools required: drill, flat screwdriver, Phillips screwdriver, razorblade, and hammer, and a rag and a plastic adhesive are recommended.Note: Some minor modification of the door panel or handle kit may benecessary to ensure a perfect fit. This is an aftermarket part.

Step 1 (removing the door panel): Remove the screws from the door panel.After all of the screws are removed, carefully pry the panel from thedoor using the flat head screwdriver (use of a rag is recommended toprotect the paint). The panel will pry loose with ample pressure(multiple clips attach the panel to the door). Once loose, lift up onthe panel until it is above the lock mechanism. Once the panel is loose,carefully remove any electrical clips. Next, disconnect the rod that isattached to the door handle. Slide the clip to the side off of the rod.The plastic clip simply clips onto the rod. Once unclipped, the rod willlift out of the handle.

Step 2 (door handle removal): Start by lying the door panel down on aflat surface, backside facing up. Using a large drill bit, razor knife,or other tool, remove the tops off the plastic rivets (e.g., typically 6rivets+/−). Carefully drill or cut only the rivets and handle housing asnecessary, taking care not to drill through the door panel itself. Onceall the rivets have been drilled or cut out, the handle housing willeasily detach from the door panel. Use the razor blade to remove anyexcess plastic shavings on the panel.

Step 3 (installing the new handle on the door panel): Line the holes andslots of the replacement housing up with the posts (typically two) andtabs (typically 3-4) of the door panel. Press the housing down until itis flush with the panel (some minor modification may be necessary withthe razor blade). Ensure that you are installing the correct handle(e.g., Driver/Front, Passenger/Rear, etc). An adhesive such as a twopart epoxy or adhesive tape may be applied to one or more locations(such as the plastic weld locations) to help secure the replacementhousing and eliminate gaps. Once the handle is lined up and pressedflush, using the flat head screwdriver (or a socket), press the providedpush nut retainers down the posts until the handle housing is tight onthe door panel. Next, use a 1/16^(th) inch drill bit to drill throughthe base of the lowermost tab that protrudes through the bottom of thehousing. Make sure the housing is pressed down flush when drilling thetab to avoid a gap between the housing and the door panel. Once drilled,insert the provided cotter pin. Using a screwdriver, bend and manipulatethe cotter pin around the tab.

As an alternative to the use of a cotter pin, use the screw provided andscrew into the tab (try to use an angle that tightens the handle to thepanel). Do not over tighten and make sure you do not screw into thehousing. Make sure the housing is pressed down flush when screwing thetab to avoid a gap between the housing and door panel.

As an alternative to, or in addition to, the use of retainers on thepost(s) and cotter pin or screw at the tab(s), small screws (preferablywith washers) may be installed into one or more of the former plasticrivet points. When tightening the screws do not use a drill and do notover tighten, and stop when the screw is snug. Be careful not to screwthrough the panel.

Now that the handle housing is completely installed, you can replace thedoor panel on the vehicle. Follow the removal instructions in reverse.

Typical customer instructions for the repair of broken door handles on aJeep Commander type vehicle may include the following. In this example,the original handle lever is to be removed and reused, and theinstructions include steps for installation of the lever in thereplacement housing.

Tools required: drill, flat head screwdriver, Phillips head screwdriver,razor blade, and hammer. Note: “Before” and “After” pictures arerecommended to ensure that you install the handles in the correctdirection. The housings appear similar; and incorrect installation mayresult in loss of hardware.

Step 1 (removing the door panel): Remove the screws from the door panel.After all of the screws are removed, carefully pry the panel from thedoor using the flat head screwdriver. The panel will pry loose withample pressure. Once loose, lift up on the panel until it is above thelock mechanism. Once the panel is loose, carefully remove any electricalclips. Next, disconnect the rod that is attached to the door handle.Slide the clip to the side off of the rod (the plastic piece simplyclips onto the rod). Once unclipped, the rod will push down and out ofthe handle.

Step 2 (removing the door handle): Start by lying the door panel down ona flat surface, backside facing up. Using a large drill bit, razorknife, or other tool, remove the top of the plastic rivets. Carefullydrill or cut only the rivets and handle housing; do not drill throughthe door panel itself. Once all the rivets have been drilled or cut out,the handle housing will easily detach from the door panel. Use the razorblade to remove any excess plastic shavings on the panel.

Step 3 (removing handle from housing, if required): In someapplications, the handle lever will be used in the new housing (if thehandle is already included in the replacement housing, skip to step 5).To remove the handle lever, use a hammer and screwdriver to knock thepin out (watch spring carefully as it is under pressure). Once the pinis removed, the spring will fall out. You can now remove the handlelever and separate it from the old housing. Note: keeping pressure onthe spring while removing the pin is helpful and will keep the springfrom falling out. You may also remove the small rubber stopper from theold housing and place it into the corresponding tab on the replacementhousing.

Step 4 (installing the handle in new housing): Start by inserting thehandle lever into the new housing. This part can be tricky, butcarefully insert and twist to allow the handle to fit into the housingproperly. The use of force is not necessary. When faced with resistance,change your approach. Once the handle is inserted, line up the holes onthe handle with the holes on the housing. The spring has two ends: oneis straight and the other is bent. The side that is bent will beinserted into the handle and the straight side will rest against thehousing. This will have the spring sticking out (pictures show thespring at rest and out of alignment as it should be). Now use your thumbto compress the spring into alignment and begin to insert the pin.Ensure that the pin goes through the housing, handle, and spring. Nowtake the small push nut retainer and press it over the pin until itreaches the housing. Once the pin is inserted all the way, and theretainer is attached, you can test the handle in the housing beforemoving on to the next step.

Step 5 (installing new handle on door panel): Line up the holes in thereplacement housing with the posts (typically two) on the door panel.Ensure that the handle will be facing the correct direction beforecontinuing. Press the housing down until it is flush with the panel.Note: some minor modification may be necessary with the razor blade. Thedriver's side and passenger side are different. Ensure that you areinstalling the corresponding housing. Once the handle is lined up andpressed flush, using the flat head screwdriver, or a deep socket thatfits, press the provided push nut retainers down the posts until thehandle housing is tight on the door panel. Do not apply enough pressureto bend or crack the housing.

As an alternative to, or in addition to, the use of retainers on thepost(s), small screws (preferably with washers) may be installed intoone or more of the former plastic rivet points. When tightening thescrews do not use a drill and do not over tighten, and stop when thescrew is snug. Be careful not to screw through the panel.

Now that the handle is completely installed, you can replace the doorpanel on the vehicle. Follow the removal instructions in reverse.

Accordingly, the inventive method may be characterized as a method forrepairing a broken interior door handle housing on an interior doorpanel on a door of a vehicle, the broken interior door handle housingintegrated into the interior door panel by a plurality of rivets, themethod comprising removing the interior door panel from the door;removing the broken interior door handle housing from the interior doorpanel by removing the plurality of rivets and detaching the brokeninterior door handle housing to reveal a plurality of former rivetlocations in the interior door panel; installing a replacement interiordoor handle housing having a plurality of apertures corresponding to atleast some of the plurality of former rivet locations on the interiordoor panel; installing at least one screw through an aperture in thereplacement interior door handle housing and into a former rivetlocation in the interior door panel to secure the replacement interiordoor handle housing against the interior door panel; and replacing theinterior door panel on the door.

The above disclosure is sufficient to enable one of ordinary skill inthe art to practice the invention, and provides the best mode ofpracticing the invention presently contemplated by the inventor. Whilethere is provided herein a full and complete disclosure of the preferredembodiments of this invention, it is not desired to limit the inventionto the exact construction, dimensional relationships, and operationshown and described. Various modifications, alternative constructions,changes and equivalents will readily occur to those skilled in the artand may be employed, as suitable, without departing from the true spiritand scope of the invention. Such changes might involve alternativematerials, components, structural arrangements, sizes, shapes, forms,functions, operational features or the like.

Therefore, the above description and illustrations should not beconstrued as limiting the scope of the invention, which is defined bythe appended claims.

What is claimed as invention is:
 1. A method for repairing a brokeninterior door handle housing on an interior door panel on a door of avehicle, the broken interior door handle housing integrated into theinterior door panel by a plurality of rivets, the method comprising:removing the interior door panel from the door; removing the brokeninterior door handle housing from the interior door panel by removingthe plurality of rivets and detaching the broken interior door handlehousing to reveal a plurality of former rivet locations in the interiordoor panel; installing a replacement interior door handle housing havinga plurality of apertures corresponding to at least some of the pluralityof former rivet locations on the interior door panel; installing atleast one screw through an aperture in the replacement interior doorhandle housing and into a former rivet location in the interior doorpanel to secure the replacement interior door handle housing against theinterior door panel; and replacing the interior door panel on the door.2. The method of claim 1 wherein the step of removing the brokeninterior door handle housing from the interior door panel by removingthe rivets and detaching the broken interior door handle housingcomprises removing the rivets with a drill.
 3. The method of claim 1wherein the step of removing the broken interior door handle housingfrom the interior door panel by removing the rivets and detaching thebroken interior door handle housing comprises removing the rivets with arazor knife.
 4. The method of claim 1 wherein the interior door panelfurther includes a tab extending from the interior door panel through acorresponding aperture in the broken interior door handle housing, andthe step of installing a replacement interior door handle housing on theinterior door panel comprises installing the replacement interior doorhandle housing on the interior door panel such that the tab on theinterior door panel extends through an aperture in the replacementinterior door handle housing.
 5. The method of claim 1 wherein the stepof installing a replacement interior door handle housing on the interiordoor panel further includes applying adhesive between the interior doorpanel and the replacement interior door handle housing.